106682-4650 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066824650

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106682-4650 1066824650

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Service parts 106682-4650 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-2080

3. GOVERNOR 105447-0731

4. SUPPLY PUMP 105237-1541

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0390

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4433

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 26.0(265)

13. NOZZLE-HOLDER

14. NOZZLE 105025-0900

15. NOZZLE SET

Include in #1:

106682-4650 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106682-4650 1066824650

Zexel num

Bosch num

Firm num

Name

106682-4650

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000

Overflow valve 131424-6520

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3 2.95 3.05

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 16.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 470 465 475

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.1+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 34 30.5 37.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 17.9+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 435 435 475

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Minimum - maximum speed specification (2)Target notch: K (3)RACK LIMIT: RAL (4)Idle sub spring setting: L1. (5)Variable speed specification: idling adjustment
----------
K=16 RAL=17.9+0.2mm L1=6-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Stopper bolt setting
----------

----------
a=58deg+-3deg b=(2deg)+-5deg c=(37deg)+-5deg

Stop lever angle

F:Full load I:Idle S:Stop
----------

----------
a=26.5deg+-5deg b=(38deg)+-5deg c=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

Bearings
Anti-Friction Bearings
When an anti-friction bearing is removed, cover it to keep out dirt and abrasives. Wash the bearings in nonflammable cleaning solution and allow them to drain dry. The bearings may be dried with compressed air, but DO NOT SPIN THE BEARING. Discard the bearings if the races and balls or rollers are pitted, scored or burned. If the bearing is serviceable, coat it with oil and wrap it in clean paper. DO NOT unwrap new bearings until time of installation.The life of an anti-friction bearing will be shortened if not properly lubricated.Double Row, Tapered Roller
Double row, tapered roller bearings are precision fit during manufacture and the components are not interchangeable. The cups, cones and spacers are usually etched with the same serial number and letter designator. If no letter designators are found, wire the components together to assure correct installation. Reusable bearing components should be installed in their original positions.Heating Bearings
Bearings which require expansion for installation should be heated in oil not to exceed 121°C (250°F). When more than one part is heated to aid in assembly, they must be allowed to cool and then pressed together again. Parts often separate as they cool and shrink.Installation
Lubricate new or used bearings before installation. Bearings that are to be preloaded must have a film of oil over the entire assembly to obtain accurate preloading. When installing a bearing, spacer or washer against a shoulder on a shaft, be sure the chamfered side is toward the shoulder. When pressing bearings into a retainer or bore, apply pressure to the outer race. If the bearing is pressed on the shaft, apply pressure on the inner race.Preload
Preload is an initial force placed on the bearing at the time of assembly.Determine preload or end clearance form the Specifications Section of this Service Manual. Care should be exercised in applying preload. Misapplication of preload to bearings requiring end clearance can result in bearing failure.Sleeve Bearings
DO NOT INSTALL SLEEVE BEARINGS WITH A HAMMER. Use a press, if possible and apply the pressure directly in line with the bore. If it is necessary to drive on a bearing, use a driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part.